Internal form and reinforced concrete construction



H. M.' HADLEY 2.179.554

Filed March 24, 1936 2 Sheets-Sheet l Nom M, 1939.

` INTERNAL FORM AND REINFORCED CONCRETE CONSTRUCTION NOV. 14, 1939. H, M, HADLEY 2.179.554

INTERNAL FORM AND REINFORCED CONCRETE CONSTRUCTION 2 Shee'ts-'Sheet- 2 Filed March 24, 1936 N N 3x1/UOMO@ Homer M Had/ey Patented Nov. 14, 1939 INTERNAL FORM AND REENFORCED GN- CitlETE CNSTRUC'EEGN l5 Claims.

This invention relates to internal forms and reinforced concrete construction, and particularly to the construction of internal forms to be embedded in the concrete.

The advantages of hollow cellular floor and wall concrete constructions are well recognized, as the use of such construction reduces the quantity of concrete required for solid sections, and there is a consequent considerable reduction in the dead weight. This form of construction also reduces the amount of reinforcing required in floors and walls, due to the reduction in the dead weight, and the general result is a considerable reduction in the load on footings. Minor V advantages are improved insulation with respect to heat and sound. Furthermore, this construction gives opportunities in a cellular type of form construction embodied in this invention, for placing conduits in the walls and iioors for heating or for carrying electric cables, water pipes, etc. One of the objects of this invention is to provide a construction of this type, providing internal 'forms of simple construction, which can be readily set up and left embedded in the concrete, and which will give the advantages indicated above.

A type of framing for reinforced floors, and employed to a limited extent in walls, is the type of construction popularly known as the joist or rib type. In this type of construction a relatively thin slab spans transversely over longitudinally extending equidistant ribs or joists, which are narrow and relatively deep, Forms, usually of pressed metal sheets bent in the shape of an inverted letter U, are placed in such a way that the exterior of the U forms a mold for the bottom of the slab and the sides of adjoining joists. At intervals the continuity of these U-shaped metal forms is interrupted to form transverse stiffening headers as deep as the ribs and integral with them. When pouring the concrete monolithic slab, joists and headers are formed in the same operation. After the concrete is suilciently hardened these metal forms are removed. After this, metal lath is attached to the bottom of the joists, and plaster applied to the metal lath to form the ceiling.

While the construction just described above, presents a hollow cellular construction, it has many disadvantages, one of which is that plastering on metal lath is a much more expensive operation than plaster applied to a flat concrete surface; and furthermore, the plastered metal lath has no structural strength and does not act as a brace of any kind for the concrete joist. In floors that are continuous over supports with (Cl. 'Y2-66) compression forces existing at the bottom of the 'door at 'the supports, the ribs are usually of inadequate section and frequently require a special widening and strengthening. In walls subject to vertical loading, the concrete section is unsyln- 5 Ametrical, and with the ribs and metal lath on the inner side of the wall as is practically always necessary, eccentric loading and uneconomical stressing ci' the wall must result.

One of the objects of this invention is to provide a simple construction of internal forms, which can be left embedded in the concrete, and which can cooperate with other forms to produce iioors or walls with slabs von their outer sides connected by joists or webs; also to provide a consti ction of this kind in which reinforcing members for the concrete are connected to the form members that produce the cellulular construction the wall or iloor.

I am aware that cellular forms have been employed heretofore, held in place to form a cellular concrete construction, but such cells heretoiore have been merely set up and supported individuaiiy in place. In accordance with my invention, the cellular units and the reinforcing constitute a unitary structure which can be produced in a factory and set up on the job where the concrete construction is to be erected. In this way the placing of reinforcing and the setting up of the cellular forms can be accomplished in one operation; and furthermore, the reinforcing members connected as they are to the cellular units, facilitate the handling of the cellular units in multiples and without necessitating the setting up and alignment of the individual cells such as used heretofore in practice.

A further object of the invention is to produce a very useful type of internal multiple cellular type of internal forni for concrete, in which the reinforcing is combined with the cellular forms.

Further objects of the invention will appear hereinafter.

The invention consists in the novel parts and combination of parts to be described hereinafter, all. of which contribute to produce an eilcient internal form and reinforced concrete construction.

A preferred embodiment of the invention is described in the following specification, while the broad scope of the invention is pointed out in the appended claims.

In the drawings:

Figure l is a vertical section taken through a wall and an adjacent portion of the floor supported by the wall and embodying my invention.

Fig. 2 is a plan of the floor shown in Fig. 1, the wall being shown in horizontal section.

Fig. 3 is a cross-section upon an enlarged scale through a cellular unit, and illustrating reinforcing attached thereto, and embodying my invention.

Fig. 4 is a side elevation of the internal form and reinforcing illustrated in Fig. 3, with the ends of the same broken away.

Fig. 5 is a side elevation and partial section illustrating another embodiment of the invention in which the cellular units are of corrugated form, and in Which the reinforcing bars are connected to the cellular units through the medium of integral projections or brackets formed by extending the walls of the cellular units outwardly.

Fig. 6 is a vertical cross section through a floor produced with the internal form and reinforcement illustrated in Fig. 5.

Fig. 7 is a side elevation of an internal form embodying my invention, and in which the reinforcing bars are connected to the internal cellular form units through the medium of separate brackets, which are Welded to the cellular units. In this view the ends of the construction are represented as broken away.

Fig. 8 is a cross section taken about on the line 8 8 of Fig. '7, and further illustrating this construction.

Before proceeding to a more detailed description of the invention, it should be stated that in accordance with my invention, I construct an internal form, which may consist of sections of a continuous cell, or of a plurality of cellular units of substantially box-form. These sections or units are arranged in axial alignment, and if a plurality of cells are employed they may be spaced apart to form, when installed, bracing webs or headers in the concrete. The units or sections are preferably constructed of sheet material connected together by reinforcing bars, which extend longitudinally with the units, and these bars are preferably rigidly connected to the units, and preferably in such a Way that two reinforcing bars are presented at each side of a unit substantially in the plane of the side walls of the units. These reinforcing bars are connected rigidly to the units, and preferably in such a way that shearing stresses are imparted through the side walls of the units between the bars at each side. The cellular units are preferably formed of light sheet metal of substantially rectangular cross-section, but the corners of the rectangle incline or are rounded; that is to say, the part of the wall of the unit connecting a horizontal wall and a vertical wall, is preferably inclined or rounded. This is advantageous because it facilitates the spacing of the reinforcing bars at a sufficient distance from a wall of the unit to insure the presence of ample concrete embedding the reinforcing bar. The length of the cellular units may be adapted to the particular requirements of the construction to be erected, and each unit has a shellform body. Its ends may be open but are preferably closed by covers or caps with flanges fitting into or over the ends of the bodies. In practice, it would be feasible to construct the cellular forms in a factory, and to connect the units together in a line by reinforcing bars connected to the walls of the units, and although such bars can be connected directly to the walls, it is preferable to have the main reinforcing bars located at a slight distance away from the walls for the reason given above, and on this account it is preferable to provide means such as brackets or chairs for connecting the reinforcing bars to the units.

In constructing a floor or Wall, these multiple forms with the reinforcing bars connecting the units will be set up so as to cooperate with outside forms, which may be made of wood or any other suitable material. In forming a floor, the multiple internal forms are located apart so that the space between them will form joists, and at intervals, if the units are spaced apart transverse Webs will be formed by the concrete connecting these joists.

The ends of the multiple internal forms will cooperate with similar forms disposed in a vertical position in the walls.

Referring more particularly to the parts, and especially to Figs. 1 and 2, I indicates a concrete floor comprising a floor slab 2, and a ceiling slab 3 integral With each other and connected by vertical webs Il, which connect the joists 5 that extend longitudinally between the multiple forms 6.

I give a cellular form to the floor I by providing a plurality of cellular units 'I preferably having a cross-section of substantially rectangular form as indicated in Fig. 3. Each unit I preferably consists of an elongated body 8 of shell form, having covers or caps 9, which close its ends; said caps preferably consisting of plates with fianges I0, their edges telescoping with the ends of the box 8. These cell units 'I are connected together in a multiple form construction by means of longitudinal reinforcing bars II, and these bars I I are preferably located substantially in line with the side walls I2 (see Fig. 3), said walls I 2 being in a substantially vertical plane, and connecting to top and bottom Walls I3 and Ill by means of inclined or curved extensions I5 of the horizontal walls. The reinforcing bars II are preferably located at a point which would coincide nearly with the angles of the rectangular cross-section if the side Walls I2 and the horizontal Walls I3 were extended to intersect.

The reinforcing bars II are preferably connected by diagonal braces I6 of metal, which pass through the units at the inclined or curved points I5, and at these points I 'I the braces I 6 may be Welded to the walls of the units. The ends of these braces are attached to the bars I I, by wrapping the same around them, or in any other suitable manner. desired, outside reinforcing members I8 may be wrapped around the outsides of the units and attached to the bars II. These outside reinforcements I8 preferably include horizontal extensions I9 that are in contact with the outer side faces of the top and bottom walls of the units and may if desired, be Welded to these walls. I provide means for rigidly holding the bars I I to the units l. In Figs. 3 and 4 I illustrate means for accomplishing this, which consists of tWo zig-zag bars 2li, which are welded at their inner angles ZI to the side walls I2 of the units, and at their outer angles 422 to the adjacent sides of the reinforcing bars I I. Although the bars II are indicated as round bars, of course, if desired, bars of square cross-section can be employed.

In order to enable the depth of the units to be adapted for forming oors of different depths, or Walls of different dimensions, I prefer to construct the units 'I so that the top and bottom walls I3 and Id are separable and distinct from the side walls I2, the side walls I2 being provided with anges IEa at their upper and lower edges, Which form seats for the inclined or curved In addition to this, if

vextensions l5.V In making the units these Walls l2 can have any desired depth for the reasons stated. `At the flanges lZa the top and bottom Walls are preferably spot welded to the side Walls.

Instead of employing the side bars 20 as illustrated in Figs. 3 and 4, I may form chairs or brackets 23 for supporting the longitudinal reinforcing bars 2d as illustrated in Figs. 5 and 6. In this type of construction the brackets or chairs 3 may be formed integrally With the Walls of the units 25.

Furthermore, if desired, the Walls of the units 25 may be greatly stiffened by forming them with corrugations 26 as illustrated in Figs. 5 and 6. These corrugations, of course, extend transversely around the units. The chairs or brackets 23 are preferably located at the ends of the units, and also at one or more intermediate points along their length. The chairs 23 are formed so as to present rudimentary sockets 27 in which the reinforcing bars 2li rest. At the points on the units Where the brackets or chairs 23 occur, they may be left uncorrugated.

In Figs. '7 and 8 a construction is illustrated for the units, in which the sections la and ib` of the units are corrugated and provided with substantially plain ends 2B that are telescoped together. These two views l and 3 also illustrate the use of brackets or chairs 29 formed as separate pieces from the unit, and these brackets are mounted as saddles on the outer sides of the walls of the units, and secured thereto preferably by spot Welding.

As illustrated in Fig. 1, the cellular unit l is located near a Wall 3B of the construction, and is placed so that there is a considerable distance between the end of this unit and the plane of the Wall, so as to leave an end space to be filled with the concrete as at 3l in Fig. 1.

In the construction of the wall 3i), a pluralyity of units 32 are arranged in vertical rows as indicated in Fig. 2, with spaces between them to form vertical Webs 33 in the concrete of the Wall, which will operate as columns.

There is a considerable advantage arising from the use of the inclined or curved extensions I5 on the units, because by cutting the corners or angles out of the cross-section of the unit in this Way, the concrete flows up against the form so as to present a curved or inclined face Where a horizontal member such as the floor slab or ceiling slab connects with a vertical web or joist. This avoids forming a sharp angle in the concrete, which is most desirable, an-d greatly strengthens the structure.

While I have described the units as being composed of sheet metal, if desired, these units may be made Wholly or in part of ply Wood, metal lath, or heavy paper over wire mesh.

If desired, it is obvious that transverse partitions may be used in the cellular units Wherever desired. Such partitions would be used as braces Wherever necessary if the cellular units are of considerable length. Substantially horizontal cross bars or Wires could also be placed, running through the cellular units if desired.

One of the advantages arising from employing these multiple unit forms that constitute my invention, is that the instability of separate and separately placed cellular units is avoided. In practice, where separate and separately placed units are employed, the pressure of the concrete tends to displace them. With my improvement the cellular units are all rigidly secured in place, and a considerable number of them can be set up ready for pouring the concrete with a minimum amount of manual labor.

The rounded angles at the points l5 of the units, is also most advantageous because the pressure on these inclined or curved portions ten-ds to balance the pressure of the concrete on the cellular unit. In other Words, the pressure of the concrete on the rounded corners or angle extensions I5, operates to brace and stilfen the side Walls l2, and overcomes any tendency of these Walls to be bulged inwardly by the pressure of the concrete.

In practice, of course, reinforcing bars additional to bars il may be placed in the joist 5, but as such reinforcements form no part of this invention, they are omitted from the drawings.

In Fig. i, the dotted lines 30a. and 3a indicate the removable external forms that would be used in supporting the poured concrete on the inner side of the Wall and on the under side of the floors.

If desired, the internal form may consist of a continuous cell formed of sections, the ends of which would be connected together in any suitable manner. In Fig. 5 I illustrate a construction in which the ends of the section Will telescope each other. In other Words, in practicing the invention, the caps on the cellular units can be omitted and the ends of the bodies of the units connected together to form a continuous cell extending throughout the entire length of the form.

It is understood that the embodiment of the invention described herein is only one of the many embodiments this invention may take, and I do not Wish to be limited in the practice of the invention, nor in the claims, to the particular embodiment set forth.

What I claim is:

1. In a form for reinforced concrete construction, the combination of a plurality of cellular units having sheet-form Walls with substantially vertical side faces, said units disposed in substantially axial alignment, a plurality of reinforcing bars extending longitudinally with said units located substantially in the plane of the said vertical sides but removed from the Walls of the units, means for rigidly securing the reinforcing bars to the said units so as to positively hold the units in xed position with respect to one another and with respect to the reinforcing bars, and means for conning the placed concrete so as to enable the units and the reinforcing bars to become embedded in the placed concrete.

2. In a form for reinforced concrete construction, the combination of a plurality of substantially shell-form units having sheet-form Walls and constituting internal forms for the concrete, said units located in substantially axial alignment, reinforcing bars extending longitudinally with the units with brackets rigid with the units for securing the bars to the units and operating to hold the bars removed from the Walls of the units, diagonal braces connecting the said bars, and means for confining the placed concrete so as to enable the placed concrete to cover the upper and lower sides of the units and embed the said longitudinally extending reinforcing bars.

3. A form for reinforced concrete construction, constructed as described in claim 2, in Which the corners of the cellular units are rounded and the said brackets are formed integrally with the walls of the said units.

4. A cellular member to be embedded in concrete, having substantially vertical side walls, substantially parallel reinforcing bars located substantially in the plane of the said side walls but removed from the same, and means for rigidly connecting the reinforcing bars to the cellular` form member so that the cellular form and said reinforcing bars may be handled as a single unied assembly.

5. An internal form adapted to be embedded in concrete and consisting of a plurality of cellular units of substantially rectangular cross section having substantially vertical side Walls and substantially horizontal top and bottom Walls with inclined extensions connecting the horizontal and vertical walls, reinforcing bars extending longitudinally substantially in the plane of the said vertical Walls, and located adjacent the said inclined extensions, and diagonal braces extending through the units and connecting the said bars.

6. An internal concrete form constructed as described in claim 4, in which the top and bottom walls are formed as separate pieces distinct from the side walls, thereby enabling side walls of different vertical height to be employed to give the units different vertical depths.

7. An internal form for concrete, to be completely enveloped and embedded in the concrete,

i consisting of a cellular unit of substantially rectangular cross section having substantially vertical side walls and substantially horizontal top and bottom walls with inclined extensions connecting the side walls and the horizontal walls, and braces extending diagonally through the units at the said inclined extensions and projecting outwardly beyond the Walls of the unit for connection to reinforcing members for the concrete.

8. An internal form for reinforced concrete to be completely enveloped and embedded in the concrete, consisting of a plurality of cellular boxform units arranged in axial alignment and spaced apart, said units having substantially Vertical side Walls and substantially horizontal top and bottom walls, reinforcing bars extending longitudinally with the units, and means for rigidly securing the reinforcing bars to the walls of the units so that the reinforcing bars are held away from the walls of the units so as to form spaces for the concrete between the bars and the side walls of the units.

9. For use in reinforced concrete construction, an internal form member having a light thin walled cell, and a plurality of reinforcing members spaced from, and extending longitudinally with, and rigidly secured to, the internal form, so that the form member and reinforcing members may be handled together as a single unified assembly.

10. In a reinforced concrete construction, an internal form having a cell therein, and a plurality of reinforcing members spaced from, and extending longitudinally with, the internal form, concrete completely enveloping and embedding the internal form and embedding the reinforcing members, and diagonal braces extending through the form and connecting the reinforcing members.

11. For use in reinforced concrete construction, an internal form to be embodded in concrete, consisting of shell-form sections connected together, a plurality of reinforcing bars extending longitudinally with the form on its exterior and spaced therefrom, and means for rigidly connecting the reinforcing bars with the internal form. l2. An internal form unit for embedment in concrete, having a pair of vertically spaced side bars at each side, a hollow cell extending longitudinally between the pairs of side bars, and having substantially vertical walls rigidly connected to the side bars and located substantially in the plane passing down through the side bars, said side bars enabling the cell to be handled with the bars as a unit in setting the same up in the space to be concreted, said cell having inclined corners adjacent the bars operating to enlarge the concreting space immediately surrounding each bar so that said bars become embedded in the concrete that embeds the cell and constitute reinforcing for the concrete.

13. [in internal form unit for embodment in concrete, having a pair of vertically spaced side bars at each side, a plurality of hollow cells spaced apart and extending longitudinally between the pairs of side bars, and having substantially vertical walls rigidly connected to the side bars and located substantially in the plane passing down through the side bars, said side bars enabling the cells to be handled with the bars as a unit in setting the same up in the space to be ccncreted, said cells having inclined corners adjacent the bars operating to enlarge the concreting space immediately surrounding each bar so that said bars become embedded in the concrete that embeds the cells and constitute reinforcing for the concrete.

14. An internal form unit to be completely enveloped in concrete, having a pair of vertically spaced side bars at each side, a plurality of hollow cells spaced apart and extending longitudinally between the pairs of side bars and having substantially vertical side Walls located substantially in the plane passing down through the side bars, zig-Zag stiifener bars secured to the said side bars and secured to the said vertical side walls of the cell, said side bars enabling the cells to be handled with the bars as a unit in setting the same up in the space to be concreted, said cells having inclined corners adjacent the bars operating to enlarge the concreting space 'nimediately surrounding each side bar so that said side bars become embedded in the concrete that envelops the cells, and constitute reinforcing for the concrete.

l5. An internal form unit to be completely enveloped in concrete, having a pair of vertically spaced side bars at each side, a plurality of hollow cells spaced apart extending longitudinally between the pairs of side bars and out of contact with said bars, said cells having inclined corners adjacent the side bars operating to enlarge the concreting space immediately surrounding each bar, and means for connecting the bars and the cells, said means enabling the cells to e handled with the bars as a unit in setting the same up in the space to be concreted, said side bars becoming embedded in the concrete that embeds the cells and constituting reinforcing for the concrete.

HOMER M. HADLEY. 

